'90 Ford Escort RS Turbo 2.0 ZVH

[Maxwell]

I'm new to the site. Had a cousin who told me to stick my build thread up here!

Well I'm john from just outside belfast in Northern Ireland. I had a Subaru Impreza WRX import and got rid of it, as it was a pain in the hole on fuel and few other reasons, but ended up doing a deal on this Escort RS Turbo 90 spec.

its been repaired in the past so paint aint the best, but it would do rightly!

few mods:

Raised bonnet
Pace FMIC
Bailey dump valve
red silicone hosing
boost guage
-31 wastegate actuator
k&n filter
scorpion from turbo right back into a 3" outwardly rolled
Lockwood dials









check out the old school Graphic equaliser lol


so i ended up buying a 2.0L zetec bottom end and bought a ported and polished head off Turbohiggins - so roll on the ZVH conversion and some more reliable power



good bores


standard 2.0L zetec pistons need milled down by 0.050"




posey head and block pic




big shiny inlet ports


big none shiny exhaust ports


only other plans is front and rear strut brace and going to make it a 2 seater and tidy the paint up a lil!

Got myself an 1800 zetec sump, as the 2.0L sump has the oil well in the opposite direction. It needs modified



And also got the water pump conversion plate (you need 1.6 cvh water pump but it doesnt sit flush or doesnt have correct bolt pattern to fit on the zetec block). Also got the breater block up bung and plate too



Saved myself a fortune on the price, as well as postage

Pistons are currently in a machinists getting 0.050" skimmed off the tops, to drop the compression down to around 8.0:1 and also they are making me the 4 oil gallery block off dowells (3x16mm and 1x14mm)

I also need to get a 1.3 cvh tensioner and then i need to drill out the CVH flywheel to 11mm, to fit the zetec flywheel location holes

Spent today chasing up a few things. Collected my pistons which had 0.050" (1.25mm) skimmed off the tops which drops the compression down to 8.0:1. Also collected my oil gallery blocking dowells and i had an oil rerurn pipe put into my sump after a location hole was drilled and tapped. All thanks to a local engineering place. They also zipped off a part of the casting on the zetec sump, which causes problems during the fitting of the turbo down pipe

So i blocked off the breather at the front of the block and hammered in the blockers for the oil galleries!






Dowells about to be driven home


Flushness




To finish the bottom end, i just need 1800 zetec dipstick, 1800 zetec oil pick up pipe, a breather pipe located on the back of the block and then need to get the water pump conversion plate fitted!

Then need a cam, cambelt, 1300 cvh tensioner and head gasket - and then everything cleaned painted and built up and then thats it ready for the conversion

Picked myself up a few more goodies

Piper 285T2 cam
Sierra Cosworth 3 spoke Steering wheel
Polished Front Strut Brace (which will be getting powder coated)





out with the old


and in with the new


then stuck the strut brace on for a curse word arty pic haha


and as I'm making it a 2 seater, i went about ditching the interior




so the interior is for sale

[Maxwell]

Then i prepped the block for the fitting of the water pump conversion plate. Because you have to use a CVH water pump, the location holes on the zetec block don't match up. So you have to twist the plate to a different orientation to suit this. But the only available places, leave you to drill through a thin wall on two of the holes. To to help this you get some trusty chemical metal its good as the rough casting is a good etching for the chemical metal to grip onto





So then i trailed the car in and started to strip the engine bay to keep the ball rolling! Enjoy

Before



After




Bumper, headlight removal and wiring loom stripping back



Needs little tidying




My saxo is so cool it wears an rs turbo bonnet backwards lol

[Maxwell]

Just stripped off the bits i need for the conversion!!

Before:


After:



The old school mechanical ABS unit (for the bin, in favour of a bias valve)


For the powdercoaters:

[Maxwell]

I'm having a nightmare with the block. Nitromors'd it and about 99% of the paint came off. Need it 120% clean and grease free before I paint it!! Pulled the crank out while I was at it!!





Waiting for a guy to mix up some paint for my block. So i got the hold of my top engine mount and modified it to suit the zetec block

Two out of the three hole match up, where as the other is way off pitch (as you can see)



So to mod it, i cut off the unused lug and located it to the extra mount hole on the zetec block. Here is my mates 1.8 zvh and an example what mine should have looked like!



But of course my handy skills where not up to scratch (but good enough for the job)



So i just had to get a piece welded in and get my mate to tack it together for me. I tried a spot of welding and of course it wasnt up to scratch lol. My mate tidied it as be he could



And now the finished product, needs the welds buffed a wee bit and send it off to get powder coated!!

[Maxwell]

Took off early this morning and headed for Malin town in Donegal!! I met up with a guy off passionford and he sorted me out with a complete EFI set up from a fiesta rs turbo



195 superchipped fiesta rst ecu




Then efi inlet, tb, fuel rail and even through in an AP 4 paddle (needs re-lined)



And then there is injectors, edis module, ignition pack, mega leads, fse fuel pressure regulator, fiesta rst engine loom and injector loom



Then he miss placed the crank position sensor so he fired in a set of mahle c20xe pistons (so my 2.0, might be a 2.1 when finished lol)